Catalytic solutions for improving refining competitiveness by Advanced Refining Technologies
About ART Who we are Grace-Chevron joint venture leveraging
CLG’s hydrocracking catalyst technology and CB&I’s process technology
What we have A complete portfolio of hydroprocessing
catalysts
Substantial resources dedicated to customer support and product development
What we do Improve the operation and profitability of our
customers in the petroleum refining industry
How we do it Exceptional design of catalyst systems
Fully integrated technical support teams
Why we do it To provide a single point of contact for
refiners hydroprocessing catalyst needs
ISOCRACKING®
ISOCRACKING®
Comprehensive line of catalyst systems for:
Distillate hydrotreating: Naphtha / Cracked Naphtha: StART Catalyst System ®
Kerosene, Jet and ULSD: SmART Catalyst System ®
FCC Pretreatment: ApART Catalyst System®
Hydrocracking: ISOCRACKING® Catalyst System
Lubes Production: ISODEWAXING ® Catalyst Systems
ISOFINISHING ® Catalyst Systems
Resid hydroprocessing: Up Flow Reactor (UFR) and On-Stream Catalyst
Replacement (OCR) Systems
Ebullating Bed Resid Systems
Broad Product Portfolio
Vacuum
Gas Oil
Naphtha AT™ Series
AT™ Series DX™ Series
Cru
de T
ower
Coker Naphtha
StART Catalyst System®
SmART Catalyst System®
Kerosene
& Jet
AT Series
DX Series
ICR® Series HOP® Series
GR® Series LS™ Series ULS™ Series HSLS™ HCRC™
Hydrocracking
ApART Catalyst System®
AT, DX Series FCC Pretreat
Vacu
um T
ower
Fixed Bed Resid
Diesel
Lubes ISODEWAXING®
ISOFINISHING®
ICR® Series
ICR® Series
ICR® Series
Ebullating Bed Resid
Global Presence
ART Global Facility R&D Center Sales/Tech Service Office Manufacturing Site
Manufacturing Sites
Lake Charles, LA USA Chicago, IL USA Curtis Bay, MD USA Hitachi, Japan (Tolling) Shuaiba, Kuwait (Tolling - KCC)
Research and Development
Curtis Bay, MD USA Columbia, MD USA Chicago, IL USA Richmond, CA USA Honmoku, Japan
Sales/Technical Services Offices
Columbia, MD USA The Hague, Holland Richmond, CA USA Shuaiba, Kuwait Chicago, IL USA Dubai, UAE Houston, TX USA Tokyo, Japan Worms, Germany Hong Kong Moscow, Russia Singapore Milan, Italy Mumbai, India
Hydroprocessing Expertise Based On First Hand Knowledge Of Refinery Operations
Modern Hydro
Cracking
Fixed Bed Resid
Conversion
Lube Base Oil
Production
EbullatingBed Resid
Conversion
1960s 1970s 1980s 1990s
Insert Yo Company
Here
Lube Isodewaxing
1950s
Initial ART Hydro
Processing Catalysts
2010’s
Conventional ART Hydro Processing Catalysts
Catalyst developments go hand in hand with process developments
The Leader in Hydroprocessing Catalysts
Strong position for ART
#1 FBR segment
#1 EBR segment
#2 HCR segment
ART
Comp A
Comp B
Comp C
Others
ART engineered catalyst systems and operations support lead to long term customer satisfaction
Global Hydroprocessing Market Estimate: 350M LBS
Commitment to Research & Development Over 60 years of hydroprocessing catalyst experience
New Catalysts Launched per Year Hydrocracking Lubes Ebullating
Bed Resid Fixed Bed
Resid Distillate
Hydrotreating
2-3 1-2 1-2 1-2 2-3
Testing supports innovation and also allows ART to better understand larger refinery picture
Alignment of Catalyst Segments
DHT
Lubes
HCR
FBR
EBR
Hydrocracking (HCR) • Contaminant removal critical to
maintain HCR catalyst activity • Maximum saturation of feed
molecules for volume swell
Customers Profit from Maximum
Conversion of Feed to High Quality
Products
Fixed Bed Resid (FBR) • Contaminant removal essential
for catalyst activity and downstream RFCC profitability (where applicable)
• Maximum desulfurization activity for transportation fuel specifications
Ebullating Bed Resid (EBR) • Contaminant removal central to
control of sediment formation • Maximum desulfurization activity
for transportation fuel specifications
Lubes • Contaminant removal vital
to protection of downstream precious metals catalysts
• Wax concentration and aromatic saturation to upgrade lower value stocks to higher value
Distillate Hydrotreating (DHT) • Contaminant removal crucial for
maximum unit run length • Maximum desulfurization for
transportation fuel specifications
• Balanced aromatics saturation activity for volume swell
Diesel Fuel Specifications for EU
Hydrocracker has to produce cleaner products from nastier feeds
Date of Implementation 1994 1996 2000 2005 2008 2009 2013 2014
Emission Stages Euro 3 Euro III
Euro 4 Euro IV Euro V Euro 5 Euro VI Euro 6
Cetane Number, Min. 49 (Temperate) / 45-47 (Arctic) 51 (Temperate) / 47-49 (Arctic)
Sulfur, ppm, Max. 2000 500 350 50 10
Polyaromatics, Wt %, Max. 11 8
Density @ 15°C (60°F), kg/m3, Max.
860 (Temperate) / 840-845 (Arctic) 845 (Temperate) / 840-845 (Arctic)
T95, °C, Max. 360
Cold Filter Plugging Point (CFPP), °C, Max. +5 (Temperate) to -44 (Arctic)
Cloud Point (CP), °C, Max. -20 to -34 -10 to -34
Chevron History – Where we are today
• 6 wholly owned Chevron refineries have ~ 73 hydroprocessing reactors (41 high pressure and 32 < 1000 psi)
• 6 partially owned Chevron refineries (Caltex) have 40 hydroprocessing reactors
• Over 70 customers worldwide currently running ART HCU & Lubes catalysts
Contaminant Removal Improves Catalyst Function
Unplanned Shutdowns
Lost Revenue
Pressure Drop
Selectivity Loss
Activity Loss
ART allocates significant R&D resources for continuous product improvement Superior contaminant removal technology in segments with more severe
operation rapidly transferred to other segments
Contaminant Source Ni + V High End Point Feed
Si Silicon Antifoam (cokers)
Na, Ca Caustic contamination Poor desalting Sea water contamination
FeSx Cu, Cr, Ni, Zn Corrosion Products
As Arsenic in Crude
P Corrosion inhibitors Well fracturing fluids
Asphaltenes Residuum
Protecting downstream catalysts extends run lengths or enables processing of lower cost feedstocks
Grading and Guard Catalyst Systems • ART offers specially designed guard catalysts to protect
downstream catalysts from fouling and poisoning
Pressure drop control
– Ring shaped macroporous particulate traps provide internal and external void space
– Ring shaped active catalysts provide high external void space and activity grading
Unique guard catalysts used to trap catalyst poisons
– Macroporous catalysts with high capacity for Nickel and Vanadium
– High surface area catalysts with high capacity for Silicon
– High Ni content catalysts with high capacity for Arsenic
System Activity Cycle Length
Adsorbs Iron sulfide gums
Particulates get trapped in macropores
System design comes from first hand experience and represents an optimum balance between cycle length and activity requirements
HCR Catalyst Overview
Hydrocracking Model Diagram
Model Crude Types
Catalyst Components
Run Objectives
Operating Constraints
Unit Configuration
Customer Specific Testing Product Prices
Product Specifications
• Candidate case performance guarantee • Optimum catalyst system to maximize profits
Outputs
ART HCR catalyst performance model incorporates commercial operating data from partner operating units
Hydrocracking Pretreat Reactions
Olefins Saturation Mitigate pressure drop Easy
Demetallization (HDM) Maintain clear reaction pathways
Desulfurization (HDS) Enable aromatics saturation
Denitrification (HDN) Enable aromatics saturation Deactivates cracking catalyst
More Difficult
Aromatics Saturation Prerequisite for Hydrocracking
Hydrocracking Objectives: • Safety of Operation • Conversion of heavy feed to
lighter products • Feed flexibility • Upgrade low value stocks • Produce clean products • Volume gain • Minimum hydrogen consumption • Long operating cycle
ART pretreat catalysts are arranged to optimize preparation of feed for cracking
Expertise in Conditioning Feeds
Hydrocracking
Hydrocracking Catalyst
HDS/HDN/HDA Catalyst (NiMo)
Bottom Support
Active Guard Material
(Si,As,Ni,V)
Grading
HDS/HDN (NiMo)
Diesel
FCC Pretreat
EBR
FBR
Lubes
Grading Grading Grading Grading
Active Guard Material (Si,As)
Active Guard Material
(Si,As,Ni,V)
Active Guard Material
(Fe,Ca,Na)
Active Guard Material (PCA,N)
Active Catalyst (CoMo)
Active Catalyst (NiMo)
Active Catalyst (NiMo)
HDM Catalyst (NiMo)
Dewaxing Catalyst Active Catalyst
(NiMo) HDM/HDS Transition
Catalysts (NiMo)
Active Catalyst (CoMo)
HDS/HDN/CCR Removal Catalyst
(NiMo)
Finishing Catalyst
Bottom Support Bottom Support Bottom Support
Bottom Support
Evolution of ART products based on performance extensions in key functions across segments
Impact of ISOCRACKING® Catalyst Systems
Configuration Single Stage Two Stage, tail end distillation
Two Stage, intermediate distillation
Two Stage, intermediate distillation
Process single stage only
mainly hydrotreating then hydrocracking
mainly hydrotreating then clean hydrocracking
mainly hydrotreating then sour hydrocracking
Run length Short Intermediate Long Long
Hydrogen consumption Low Intermediate High High
Contribution of pretreat catalyst to unit objectives High High Intermediate High
Hydrocracking catalyst system mostly crystalline optimum crystalline /
amorphous system mostly amorphous optimum crystalline / amorphous system
All unit configurations achieve unmatched industry performance with ART Catalyst Systems
Hydrocracking Pretreat Catalyst Development Improved HDT Catalyst
ICR 513 Offers Significantly Higher Activity and Enhanced Stability vs. Previous Generations of HDT Catalysts
Base
1988 1996 2003 2006 2009 2011 2013
ICR 114
ICR 134
ICR 154
ICR 178
ICR 179
ICR 511 ICR 512
ICR513
1972
+ 10
+ 20
+ 30
+ 40
HD
N A
ctiv
ity, °
F
ISOCRACKING® Catalysts Portfolio Relative Activity and Selectivity
Activity
Sele
ctiv
ity
ICR 240
ICR 142
ICR 162
ICR 160
ICR 210
ICR 147
ICR 141
ICR 139
ICR 183
ICR 155
ICR 245
ICR 177
ICR 180
ICR 185
Base Metal Hydrocracking
Catalyst Portfolio
Max. Diesel Diesel/Kero Kero/Jet Max. Naphtha
ICR 142v2
ICR 250
ICR 120
ICR 214
ICR 255 ICR 188
ICR 215
ICR 191
Next Generation ISOCRACKING® Catalyst Improved Diesel yield ICR 180 and ICR 188 versus ICR 162 ~ 60%
conversion ICR 180 ICR 188
WBAT, °F -10 +5
C4-, Wt% -0.2 -0.5
Light Naphtha (C5-180°F), LV % -0.2 -1.2
Heavy Naphtha (180-400°F), LV % -1.5 -6.5
Jet (400-530°F), LV % -0.7 +0.5
Diesel (530-700°F), LV % +2.7 +5.2
Mid-Distillates (400-700°F), LV % +2.0 +5.7
ICR 180
Max. Diesel Diesel/Kero Kero/Jet Max. Naphtha
ICR 188
ICR 162
Next Generation ISOCRACKING® Catalyst Improved Diesel yield ICR 180 and ICR 188 versus ICR 162 ~ 60%
conversion ICR 180 ICR 188
WBAT, °F -10 +5
Jet / Smoke Point, mm Base Base
Freeze Point, °C Base > -10
Heavy Diesel / Pour Point, °C -7 -24
Cloud Point, °C -3 -5
Cetane Index Base Base
UCO N / S, ppm Base / Base Base / Base
Pour Point, °C -12 -62
ICR 180
Max. Diesel Diesel/Kero Kero/Jet Max. Naphtha
ICR 188
ICR 162
Next Generation ISOCRACKING® Catalyst Enhanced Distillate Yield ICR 250, ICR 255 versus ICR 240 ~ 60% Per
Pass conversion 2nd Stage recycle
ICR 250 ICR 255
WBAT, °F Base -32
C4- , Wt % -0.7 -0.5
Naphtha (C5-250°F), LV % -1.3 +0.5
Jet (250-550°F), LV % -0.6 +2.6
Diesel (550-700°F), LV % +2.4 -2.1
Mid-Distillates (250-700°F), LV % +1.8 +0.5
ICR 240
Max. Diesel Diesel/Kero Kero/Jet Max. Naphtha
ICR 255 ICR 250
ART HCR Catalysts
More stringent product qualities require comprehensive catalyst formulation know-how
Understanding the chemistry and kinetics across the segments yields greater HCR catalyst system performance
Substantial R&D resources dedicated to customer support and product development
Ground floor knowledge of adjacent refinery operations
Proficiency from meter to nanometer level in all ART ISOCRACKING® catalyst systems
Understanding of the numerous factors influencing optimum catalyst configuration
Improvements in pore architecture that lead to superior catalyst performance
Proper position of individual components that lead to better performing catalyst systems
Long term satisfaction of ART customers is both an indicator of success and a goal of the business
Recommended
